EP1669486B1 - Vliesstoff als einlage - Google Patents

Vliesstoff als einlage Download PDF

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Publication number
EP1669486B1
EP1669486B1 EP20040723327 EP04723327A EP1669486B1 EP 1669486 B1 EP1669486 B1 EP 1669486B1 EP 20040723327 EP20040723327 EP 20040723327 EP 04723327 A EP04723327 A EP 04723327A EP 1669486 B1 EP1669486 B1 EP 1669486B1
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EP
European Patent Office
Prior art keywords
reinforcing
yarns
base fabric
woven base
fibers
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
EP20040723327
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English (en)
French (fr)
Other versions
EP1669486A4 (de
EP1669486A1 (de
Inventor
Akira c/o Kurashiki Boseki K.K. KASUYA
Wataru c/o Kurashiki Boseki K.K. HORIMOTO
Kazuya c/o Kurashiki Boseki K.K. KUSU
Yoshikazu c/o Kurashiki Boseki K.K. MAEGAWA
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kurashiki Spinning Co Ltd
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Kurashiki Spinning Co Ltd
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Filing date
Publication date
Application filed by Kurashiki Spinning Co Ltd filed Critical Kurashiki Spinning Co Ltd
Publication of EP1669486A1 publication Critical patent/EP1669486A1/de
Publication of EP1669486A4 publication Critical patent/EP1669486A4/de
Application granted granted Critical
Publication of EP1669486B1 publication Critical patent/EP1669486B1/de
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • D04H3/147—Composite yarns or filaments
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/06—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyolefin as constituent
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/002—Inorganic yarns or filaments
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D04H3/04—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D04H3/04—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles
    • D04H3/045—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles for net manufacturing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24058—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in respective layers or components in angular relation
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24058—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in respective layers or components in angular relation
    • Y10T428/24074—Strand or strand-portions
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24058—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in respective layers or components in angular relation
    • Y10T428/24074—Strand or strand-portions
    • Y10T428/24091—Strand or strand-portions with additional layer[s]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24058—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in respective layers or components in angular relation
    • Y10T428/24124—Fibers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
    • Y10T442/642—Strand or fiber material is a blend of polymeric material and a filler material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/643—Including parallel strand or fiber material within the nonwoven fabric
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/659—Including an additional nonwoven fabric
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/69—Autogenously bonded nonwoven fabric

Definitions

  • the present invention relates to a reinforcing non-woven base fabric that is used for externally reinforcing and repairing a concrete structure, and also concerns a reinforcing non-woven base fabric used for FRP.
  • a so-called high-strength fiber sheet having a specific gravity smaller than metal and strength higher than metal is inserted or bonded thereto.
  • the high-strength fibers are allowed to further increase the strength thereof when a number of fibers are arranged in a direction in which greater strength is required.
  • the high-strength fibers in a yarn state cause difficulty in handling and time-consuming tasks in aligning yarns one by one; therefore, the high-strength fibers in a sheet state are used in most cases.
  • glass fiber yarn is composed of not a single fiber, but a bunch of glass fibers, with the result that voids tend to exist between fibers. Even when the bunch of glass fibers is impregnated with the bonding-agent solution, these voids are not filled with the solution. Depending on the bonding agents, during drying and bonding processes after the impregnation, voids tend to generate inside the fiber yarns.
  • a reinforcing non-woven base fabric including a number of voids therein is used for reinforcing FRP or a concrete structure, with the result that the strength of the reinforced FRP or the reinforced concrete is lowered.
  • a bonding agent such as an acrylic resin, a nylon resin and polyester, to be normally used for bonding the high-strength fibers and the shape-retaining fibers to each other tends to absorb moisture during production and storage, with the result that the adhesive property to the matrix of the FRP or the concrete is lowered to cause a reduction in the reinforcing performance. The moisture is evaporated to expand to sometimes cause a deformation in the matrix resin and damages thereto.
  • the glass fibers that have been often used conventionally has a high specific gravity, that is, in a level of 2.5, to cause an increase in the weight per unit area as a whole and insufficient flexibility; consequently, the conventional glass fibers cause a difficulty in handling due to an insufficient following property to curved faces and the like.
  • WO02/04725 discloses a mat for reinforcing having a direction of construction, comprising: a first set of fibers laid as a ply in spaced apart parallel relationship in the direction of construction; a second set of fibers laid as a ply in spaced apart parallel relationship perpendicular to the direction of construction, the position of the second set of fibers adjacent to the first set of fibers defining a plurality of interstices; a continuous filament knitted into the interstices to provide stability; wherein the filament has a core portion and a sheath portion, the sheath portion having a melting point that is lower than a melting point of the core portion, such that sheath portion is thermally fusible to form a plurality of closed loops in which the first and second sets of fibers are entrapped.
  • EP-A-0144939 discloses a base cloth for reinforcement which comprises a warp and a weft each comprising a set for parallel yarns running in the machine direction and cross-machine direction, respectively, the weft being on at least one of the surfaces formed by the warp, and a thermoplastic weldable yam, weldable to both the warp and the weft and having a lower melting point than that of the warp and weft, the weldable yarn wound on at least one of the warp and weft and adhering the warp and the weft at a plurality of intersections there between.
  • EP-A-1125728 discloses a fiber reinforced plastic formed by integrating a fiber reinforcing material and a non-woven fabric, and having excellent shaping ability, impact resistance after molding, and excellent reliability and low cost.
  • the aim of the present invention is achieved by a complex fiber reinforcing material including a sheet-shaped fiber reinforcing material composed of reinforcing fibers, and a non-woven fabric laminated on at least one side of the fiber reinforcing material, wherein the fibers constituting the non-woven fabric pass through the fiber reinforcing material to integrate the non-woven fabric with the fiber reinforcing material.
  • US-A-2003/180514 discloses a unidirectional strengthening composite based on thread laps, wherein said thread laps consist of: a first lap of mutually parallel strengthening threads, a second lap of bonding threads composed of a fibrous core coated with a thermoplastic and running transversely to the threads of the first lap, being crossed without interlacing, said strengthening threads of the first lap being bonded, at least locally, to the bonding threads of the second lap by fusion of the thermoplastic, and optionally a third lap of strengthening threads parallel to one another and to those of the first lap and bonded, at least locally, to the coated bonding threads by fusion of the thermoplastic, the coated bonding threads of the second lap being trapped between the strengthening threads of the first lap and the strengthening threads of the third lap.
  • US-A-4,680,213 discloses a textile reinforcement adapted to be used for making laminated complexes, of the type constituted by at least one layer of reinforcing yarns.
  • the yarns are bonded together by adhesion with binding yarns, disposed transversely, in a small proportion with respect to the reinforcing yarns.
  • Reinforcing yarns are spaced apart from one another so as to form stable and undeformable holes of definite shape. Additional binding yarns are disposed on either side of each of the strips of reinforcing yarns.
  • FR-A-2,792,952 discloses a reinforcing product consisting of two sheets of reinforcing threads and linking sheet of linking threads between them.
  • the product for use as semi-rigid coherent type reinforcement framework, based on sheets of intersecting threads, is composed of primary sheet hung with reinforcing threads parallel to each other and transverse sheet of reinforcing threads intersecting (but not interlacing) with the threads of primary sheet and linked together, at least at points, by fusion with linking fibres, at least partially melted and based on thermoplastic material.
  • the product may also consist of two primary sheets of reinforcing fibers parallel between each other and between sheets, and transverse sheet whose reinforcing thread are imprisoned between the threads of primary sheets.;
  • the threads of two primary sheets can be superimposed or shifted in relation to each other, and the threads of transverse sheet are oblique in relation to the threads of primary sheets.
  • Reinforcing threads can be linked with linking threads independent of them or associated with them.
  • Reinforcing threads can be mono-strand and mesh type.
  • JP-A-2003/129366 discloses a netlike base fabric having a high intersecting point adhesive strength in a crossing part and a stable net shape and capable of readily carrying out lamination and integration with a sheet-like material and a method for producing the same.
  • Core-sheath conjugated yarns containing a thermally fusible resin as a sheath and a resin having a higher melting point than that of the thermally fusible resin by 30 °C or more as a core are used as at least one of a warp yarn group and a weft yarn group.
  • Two or more layers of the warp yarn group arranged in the sheet-like state and the weft yarn group arranged in the sheet-like state are alternately laminated on form a netlike laminate.
  • the resultant laminate is then heated at a lower temperature than the melting point of the core resin to bond the warp yarn group and the weft yarn group which are thermo-compression bonded by thermally fusing actions of the sheath resin.
  • the netlike base fabric is obtained by the method.
  • a laminated composite is prepared by bonding and laminating the netlike base fabric to one surface of the formed sheet-like material or between the two sheet-like materials.
  • the present invention has been made to solve the above-mentioned problems, and its objective is to provide a reinforcing non-woven base fabric that is free from adverse effects such as moisture-absorbing property and voids, and capable of exerting superior properties such as flexibility and light weight.
  • the present invention relates to a reinforcing non-woven base fabric comprising:
  • Reinforcing fiber yarns forming a sheet-shaped member of the present invention include carbon fibers, glass fibers, boron fibers and steel fibers, and are made of multifilaments that form a flat shape without twists.
  • the multifilaments are preferably designed to have a degree of flatness of not less than 2, more preferably not less than 10; here, the degree of flatness is defined as a ratio of the width to the thickness. Particularly preferable degree of flatness is in a range from 20 to 700.
  • the multifilaments having a degree of flatness in a range from 20 to 700 are obtained by further subjecting multifilaments that have a flat shape without twists to a fiber-opening process.
  • the fiber-opening process refers to a process in which a bunch of fibers, which is an aggregate of a plurality of filaments, are separated in the fiber width direction, and the fiber-opening process is applied to the bunch of fibers so that the width of the bunch of fibers is further widened.
  • Those yarns obtained through the fiber-opening process are referred to as fiber extended yarns.
  • the width of the original multifilaments through the fiber-opening process may be used.
  • composite fibers constituted by at least two or more polymers having a difference in melting points.
  • the composite fiber means the one in which an arrangement of respective components in a cross section is shown in various morphology, such as parallel, core-sheath , grains, radiation, mosaic, sea islands and nebula. From the viewpoint of productivity, shape-retaining property and fusion-bonding property, a two-layered product with two components having a core-sheath structure is preferably used.
  • composite fibers having a core-sheath structure in which the sheath portion is formed by a polymer having a lower melting point than that of the core portion are used.
  • the difference in melting points is preferably not less than 20°C, more preferably not less than 30°C.
  • the fibers might be cut in a fusion-bonding process; however, the application of fibers using polymers having a difference in melting points makes it possible to prevent the support fibrous member from being cut or deformed when the reinforcing fiber yarns and the support fibrous member are thermally fusion-bonded at a melting temperature on the low melting point side.
  • the support fiber member is flattened by thermo-compression processes, and the degree of irregularities in the thickness direction is consequently lowered, resulting in excellence in flatness.
  • the support fibrous member to be used in the present invention is constituted by multifilament yarns using composite fibers.
  • the application of monofilament is not desirable because the monofilament lacks in flexibility.
  • multifilaments consisting of a single fiber it becomes very difficult to remove voids derived from gaps between the single fibers as described earlier; consequently, the application of the multifilaments of this type is not desirable due to a reduction in strength due to voids.
  • multifilaments, having 30 or more filaments are preferably used.
  • the thickness of filaments is preferably in a range from 100 d to 1000 d.
  • both of a low melting point polymer and a high melting point polymer are olefin-based to form multifilaments.
  • the olefin has a very low specific gravity in comparison with other thermoplastic resins and inorganic fibers.
  • the olefin has a specific gravity of 0.90 to 0.98; in contrast, generally-used polymer materials have a specific gravity of about 1.5 and inorganic fibers have a specific gravity of about 1.8 to 2.7, which is comparatively heavy.
  • the olefin has a hydrophobic property, and has no moisture-absorbing property. Even if any absorbed moisture is present between filaments, the amount thereof is very small, and the moisture evaporates during a fusion-bonding process.
  • a combination of a polypropylene polymer serving as the high melting point polymer and polyethylene or low melting point polypropylene serving as a low melting point polymer may be used.
  • preferable examples of the structure and material include: a core-sheath structure having a polypropylene (core portion)/polyethylene (sheath portion) combination, or a polypropylene (core portion)/low melting point polypropylene (sheath portion) combination.
  • Polyolefin-based multifilaments to be used for the support fibrous member of the present invention have no bonding property to the high-strength fibers selected from carbon fibers, glass fibers, boron fibers, steel fibers.
  • any low melting point binder such as nylon and polyester, is adhered thereto so that the high-strength fibers and the support fibrous member are bonded to each other; however, in the present invention, no additional binder is required.
  • the olefin-based polymer of a low-melting portion in composite fibers is anchored onto the high-strength fibers through the fusion-bonding; thus, a sheet shape is retained through a so-called anchor effect.
  • One of the features of the present invention lies in the finding that a sheet-retaining is possible through the anchoring effect, even when low melting point olefin-based multifilaments, which inherently have no adhesive property, are used.
  • the support fiber material to be used in the present invention allows reinforced fiber yarns to be formed into a sheet shape by using a structure that is different from a fabric, that is, a non-woven fabric structure, and, for example, a method using the support fiber material as wefts and the like and a method using the support fiber material as a mesh structure are proposed.
  • the mesh structure can be manufactured through the following processes: multifilament yarns made of composite fibers, aligned in a length direction, and multifilament yarns made of composite fibers, aligned in a width direction, are alternately laminated to form two layers and more so as to form an integral sheet shape, and the laminated body is thermo-compressed by applying a temperature lower than the melting temperature of the high melting point polymer thereto. These thermo-compression processes allow the heat bonding resin in low melting point portions in the composite fibers to fuse, making it possible to provide a mesh structure having a stable shape that is free from voids.
  • the mesh structure is formed by alternately laminating two or more layers; therefore, different from a textile or knit structure, the warp is less susceptible to bending, that is, no stress concentration is imposed on the warp.
  • multifilament yarns of composite fibers it is not necessarily required for multifilament yarns of composite fibers to be used in both of the length direction and width direction; however, from the viewpoints of a reduced thickness and a stable mesh structure, multifilament yarns of composite fibers are preferably used in both of the two directions.
  • the reinforcing fiber yarns are retained into a sheet shape by the support fibrous member so that a reinforcing non-woven base fabric is formed.
  • the shape-retained sheet may be a uniaxial reinforcing fiber sheet in which a plurality of reinforcing fiber yarns are aligned in one direction.
  • the shape-retained sheet may be a biaxial reinforcing fiber sheet in which a warp sheet composed of reinforcing fiber yarns that are aligned in a length direction and a weft sheet composed of reinforcing fiber yarns that are aligned in a width direction are laminated.
  • the shape-retained sheet may be a multi-axial reinforcing fiber yarn sheet that is formed by laminating a yarn sheet made of reinforcing fiber yarns which, supposing that the length direction of the sheet is 0°, are aligned in 0°-direction, a yarn sheet made of reinforcing fiber yarns which are aligned in a + ⁇ ° - direction as well as in a - ⁇ ° -direction (0 ⁇ ⁇ ⁇ 90) and a yarn sheet made of reinforcing fiber yarns which are aligned in a 0°-direction and/or in a 90°-direction.
  • the reinforcing fiber yarns With respect to the mode in which the reinforcing fiber yarns are aligned, they may be aligned with fixed intervals or may be aligned closely.
  • a so-called shape-retaining method only by the weft which places a plurality of support fibrous members side by side in a direction virtually perpendicular to the direction (hereinafter, referred to as "reinforcing fiber yarn direction") in which the fiber yarns are aligned so that the support fibrous members and the sheet-shaped member are shape-retained through a fusion-bonding process, may be used.
  • a plurality of support fibrous members may be placed side by side virtually in parallel with the reinforcing fiber yarn direction so that the support fibrous members in a mesh state may be fusion-bonded with the sheet-shaped member and shape-retained.
  • the shape-retaining process is carried out with the support fibrous members being maintained in the mesh state, after the support fibrous members have been preliminarily formed into a desired mesh state through a fusion-bonding process or the like, the resulting mesh-state member may be superposed on the sheet-shaped member and thermally bonded with each other.
  • a structure in which at least two or more layers of reinforcing fiber yarns (for example, the group of warp yarns) and support fibrous members (for example, the group of weft yarns) are laminated with each other is preferably used so that contact points (lines) between the group of warp yarns and the group of weft yarns are fusion-bonded so as to carry out a shape-retaining process. More preferably, as shown in Fig.
  • two upper and lower layers 82 and 83 constituted by groups of warp yarns with a fixed interval are prepared, with an intermediate layer 81 constituted by a group of weft yarns made of support fibrous members being interpolated therebetween to prepare a three-layered structure; thus, a laminated structure in which the lower layer is placed with a 1/2-pitch offset so that each yarn of the lower-layer yarn group is positioned between the yarns of the upper-layer yarn group is preferably used.
  • the biaxial reinforcing fiber sheet a sheet in which reinforcing fiber yarns are preliminarily formed in a biaxial format is used and groups of support fibrous member yarns (a plurality of yarns aligned in parallel with one another or in a mesh pattern) may be fusion-bonded and shape-retained on the upper face, intermediate face and/or lower face of the sheet. Simultaneously as the biaxial reinforcing fiber yarns are formed, the support fibrous members may be inserted and fusion-bonded and shape-retained.
  • the shaping process is preferably carried out so that at least the direction of the support fibrous members and the direction of the reinforcing fiber yarns are allowed to make virtually 90 degrees.
  • the uniaxial reinforcing fiber sheet reinforcing non-woven base fabrics, obtained as described above, may be laminated with one another, with the direction of the reinforcing fiber yarns being offset by about 90 degrees, so that these may be again fusion-bonded to obtain a reinforcing non-woven base fabric.
  • the uniaxial reinforcing fiber sheet reinforcing non-woven base fabrics prior to the fusion-bonding process may be laminated with one another, with the direction of the reinforcing fiber yarns being offset by about 90 degrees, and fusion-bonded.
  • a plurality of the base fabrics may be laminated with an offset of ⁇ °-degrees (0 ⁇ ⁇ ⁇ 90) so that a multi-axial reinforcing fiber sheet reinforcing non-woven base fabric is obtained in the same manner as the biaxial reinforcing fiber sheet reinforcing non-woven base fabric.
  • the size of ⁇ may be appropriately selected depending on the number of desired laminated layers.
  • the fusion-bonding process is carried out while the laminated body of the reinforcing fiber yarns and the support fibrous members is heated and pressurized.
  • the number of the support fibrous members to be used and the gap between the parallel alignments are not particularly limited as far as the sheet-shaped member is shape-retained, and may be appropriately selected depending on the purpose for the reinforcing non-woven base fabric, the size and the method thereof, as well as on the kind, the width and the manufacturing method of the fiber extended yarns.
  • This support fibrous member which is a multifilament having a core-sheath structure, has a core portion composed of polypropylene having a melting point of 165°C and a sheath portion composed of polyethylene having a melting point of 98°C, with 60 filaments having a thickness of 680 deniers, and the specific gravity thereof is 0.93.
  • a fusion-bonding mesh was manufactured by using a heat-bonding mesh manufacturing machine as shown in Fig. 1 through the following processes.
  • the above-mentioned support fibrous member was used to form a mesh pattern in which a group of yarns 1 formed by arranging upper threads in the length direction with 2-cm pitches and a group of yarns 2 formed by arranging lower threads with 2-cm pitches so that each thread is positioned between the upper threads 1 are placed, with a group of yarns 3 formed by arranging the same threads with 1-cm pitches in the width direction being sandwiched therebetween.
  • This mesh material was fusion-bonded by using upper and lower electric heater rolls with the upper roll being set at 100°C and the lower roll being set at 80°C, under a nip pressure of 1.0 kg/cm at a line speed of 1 m/min, and wound around a take-up roll 6; thus, a mesh was obtained.
  • the thickness of the resulting mesh was 0.1 mm at the thinnest portion and 0.12 mm at the thickest portion on each intersection, with a width of the thread being set to 1.2 mm.
  • a reinforcing non-woven base fabric was manufactured by using a reinforcing non-woven base-fabric manufacturing machine shown in Fig. 2 .
  • a carbon fiber yarn (“PYROFIL (registered trademark)" made by Mitsubishi Rayon Co., Ltd.) was used as a reinforcing fiber in the length direction.
  • the above-mentioned fusion-bonded mesh 24 was inserted from under this carbon fiber yarn sheet along the sheet face, and passed between electric heater rolls 22 and 23 placed in upper and lower positions in an S-letter shape, and then fusion-bonded under a nip pressure of 1.0 kg/cm at a roll temperature of 100°C at a line speed of 1 m/min; thus, a reinforcing non-woven base fabric of the present invention was obtained.
  • Fig. 4 shows the photographs.
  • the sheath portions were fused into an integral part, while each of the core portions was maintained in its original shape. No voids such as bubbles were observed between the support fibrous members.
  • the reinforcing non-woven base fabric was bonded to the carbon fiber yarn sheet through an anchor effect by polyethylene that forms the sheath portions having a low melting point.
  • the one-direction reinforced carbon fiber yarn sheet was bound through the anchor effect by an olefin mesh that had no water-absorbing property, and since the olefin mesh was inherently thin and flexible, the resulting reinforcing non-woven base fabric was flexible, and also allowed to maintain its sheet shape. Moreover, since the olefin mesh, used for the binding material, contained no bubbles, the reinforcing non-woven base fabric was less susceptible to a reduction in its strength, even when used for FRP or the like.
  • each of yarns formed into a net is shown below for comparison.
  • the fusion-bonded mesh of 170d is sufficiently to be used so as to obtain the binding effect in the same level as the glass mesh.
  • a glass mesh was manufactured by using a glass mesh manufacturing machine shown in Fig. 3 through the following processes.
  • Glass fiber yarns (thickness: 300 deniers, specific gravity: 2.54) were used as warps to form a mesh pattern in which a group of yarns 31 formed by arranging upper threads in the length direction with 1-cm pitches and a group of yarns 32 formed by arranging lower threads with 1-cm pitches are placed so that each lower thread is superposed on each upper thread, with a group of yarns 33 formed by arranging glass fiber yarns (thickness: 600 deniers, specific gravity 2.54) with 1-cm pitches in the width direction being sandwiched therebetween.
  • the resulting mesh material was impregnated with a thermoplastic emulsion resin (ethylene-vinyl acetate copolymer resin: solid component 30 %) put in a resin vessel 36. Successively, the mesh material was passed through rubber rolls 34 and 35 (diameter: 100 mm, width: 40 cm) placed in upper and lower positions so that the excessive resin was squeezed, and dried by a drying roll at 130°C; thus, a mash formed of glass fiber yarns was obtained.
  • a thermoplastic emulsion resin ethylene-vinyl acetate copolymer resin: solid component 30 %
  • the thickness of the resulting mesh was 0.12 mm at the thinnest portion and 0.19 mm at the thickest portion on each intersection, with a width of the thread being 0.6 mm.
  • a reinforcing non-woven base fabric was manufactured by using a reinforcing non-woven base-fabric manufacturing machine shown in Fig. 5 .
  • a carbon fiber yarn (“PYROFIL (registered trademark)" made by Mitsubishi Rayon Co., Ltd.) was used as a reinforcing fiber in the length direction.
  • the above-mentioned mesh 54 made of glass fiber yarns was inserted from under this carbon fiber yarn sheet along the sheet face, and passed between electric heater rolls 52 and 53 placed in upper and lower positions in an S-letter shape, and then fusion-bonded under a nip pressure of 30 kg/40 cm at temperatures of upper and lower rolls of 150°C at a line speed of 1 m/min; thus, a reinforcing non-woven base fabric of the present invention was obtained.
  • Fig. 6 shows the photographs. There were found that there were voids among the threads forming the mesh and also that with respect to the mesh and the carbon fiber yarn sheet, the thermoplastic resin impregnated in the mesh was fused and bonded to the carbon fibers.
  • the bonding agent impregnated in the glass fiber yarns has a water-absorbing property, and the bonding agent is used for binding. Since the yarns that form the glass mesh are also impregnated with the bonding agent, and then dried, they are converged into a round shape to allow the mesh itself to have a sufficient thickness. Since the fibers forming the mesh are made of glass, the resulting reinforcing non-woven base fabric lacks in flexibility, making it difficult for the mesh to follow curved faces, when used for FRP or the like. Since there are voids in the mesh itself to be used for binding, the strength of the mesh is reduced when used for FRP or the like.
  • Yarns prepared by opening a carbon fiber yarn ("PYROFIL (registered trademark)" made by Mitsubishi Rayon Co., Ltd.) of 12K into a yarn width of about 20 mm were used as reinforcing fibers.
  • a group of upper layer yarns in which these yarns were arranged with 4-cm pitches in the length direction as upper threads and a group of lower layer yarns in which the yarns were arranged with 4-cm pitches in a manner so as to be accumulated with an offset of a 1/2-pitch so that each lower thread was positioned between the upper threads were formed.
  • An olefin-based heat bonding multifilament (heat bonding PYLEN (registered trademark) 170d; made by Mitsubishi Rayon Co., Ltd.) was used as a support fibrous member.
  • This support fibrous member which was a multifilament having a core-sheath structure, had a core portion composed of polypropylene having a melting point of 165°C and a sheath portion composed of polyethylene having a melting point of 98°C, with 60 filaments having a thickness of 170 deniers, and the specific gravity thereof was 0.93.
  • the above-mentioned carbon fiber yarns were used as warp yarn groups forming two upper and lower layers, and the support fibrous members of olefin-based heat bonding multifilament having a core-sheath structure were used as wefts.
  • an electric heater roll having a stainless outer layer was placed as an upper roll, and an electric heater roll, which had the same size with an outer layer made of heat-resistant silicon rubber, was placed as a lower roll, and the binding process was carried out by using the fusion-bonding wefts under conditions of an upper roll temperature of 100°C, a lower roll temperature of 80°C, a nip pressure of 1.0 kg/cm and a line speed of 1 m/min; thus, a fiber reinforcing non-woven base fabric with one-direction reinforced was obtained.
  • the cross section of the resulting reinforcing non-woven base fabric was observed, and in the same manner as the reinforcing non-woven base fabric obtained in example 1, the sheath portions were fused into an integral part, while each of the core portions was maintained in its original shape. Voids such as bubbles were hardly observed between the support fibrous members.
  • the carbon fiber yarn sheet was bonded through an anchor effect by polyethylene that forms the sheath portions having a low melting point.
  • the one-direction reinforced carbon fiber yarn sheet was bound through the anchor effect by olefin-based multifilament threads that had no water-absorbing property, and since the olefin-based multifilament threads were inherently flexible, the resulting reinforcing non-woven base fabric was flexible, and also allowed to maintain its sheet shape. Since the olefin-based multifilament threads themselves, used for the binding material, contain no bubbles, the strength is nor deteriorated, even when used for FRP or the like.
  • the weight of the reinforcing non-woven base fabric per 1 m 2 becomes very small. It is possible to make the amount of use of the support fibrous member to be used for binding greatly smaller. For this reason, in the case of application to FRP, the components other than the reinforcing fiber yarns can be extremely reduced.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Nonwoven Fabrics (AREA)
  • Woven Fabrics (AREA)
  • Multicomponent Fibers (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Laminated Bodies (AREA)

Claims (11)

  1. Verstärkender Grundvliesstoff, umfassend:
    verstärkende Fasergarne, wobei das verstärkende Fasergarn aus der Gruppe ausgewählt ist, die aus Kohlefasern, Glasfasern, Borfasern und Stahlfasern besteht, und ein faserverbreitertes Garn ist, das aus Multifilamenten besteht, die eine flache Form ohne Verzwirnungen bilden; und
    ein Faserträgerelement, das aus Multifilamentgarn gebildet ist, welches aus Polyolefinverbundfasern besteht, die eine Kern-Hülle-Struktur aufweisen, bei der der Hüllenteil von einem Polymer gebildet wird, das einen niedrigeren Schmelzpunkt als der Kernteil aufweist;
    wobei der verstärkende Grundvliesstoff dadurch gebildet wird, dass man die verstärkenden Fasergarne und Faserträgerelemente laminiert und heiß verpresst, wobei die verstärkenden Fasergarne mit dem Trägerelement unter Bindung einer flächigen Form verankert werden.
  2. Verstärkender Grundvliesstoff gemäß Anspruch 1, wobei das Polymer mit dem hohen Schmelzpunkt ein Polypropylenpolymer ist und das Polymer mit dem niedrigen Schmelzpunkt ein Polyethylen- oder niedrig schmelzendes Polypropylenpolymer ist.
  3. Verstärkender Grundvliesstoff gemäß Anspruch 1 oder 2, wobei die Kern-Hülle-Struktur der Verbundfasern, die die Kern-Hülle-Struktur aufweisen, eine Polypropylen(Kernteil)/Polyethylen(Hüllenteil)-Struktur oder eine Polypropylen(Kernteil)/niedrig-schmelzendes-Polypropylen(Hüllenteil)-Struktur aufweist.
  4. Verstärkender Grundvliesstoff gemäß einem der Ansprüche 1 bis 3, wobei nicht weniger als zwei Schichten desselben laminiert werden, wobei die verstärkenden Fasergarne als Gruppe von Kettgarnen verwendet werden und das Faserträgerelement als Gruppe von Schussgarnen verwendet wird.
  5. Verstärkender Grundvliesstoff gemäß Anspruch 4, der eine dreischichtige Struktur aufweist, wobei zwei obere und untere Schichten der Gruppen von Kettgarnen mit einem festen Abstand platziert werden, wobei die Gruppe der Schussgarne dazwischen eingefügt wird und die untere Schicht mit einem Versatz um ein halbes Abstandsmaß laminiert wird, so dass das Garn der Gruppe von Garnen der unteren Schicht zwischen die Garne der Gruppen von Garnen der oberen Schicht platziert wird.
  6. Verstärkender Grundvliesstoff gemäß einem der Ansprüche 1 bis 3, wobei das Faserträgerelement eine Maschenstruktur aufweist, bei der Multifilamentgarne unter Verwendung von Verbundfasern, die aus wenigstens zwei oder mehr Polymeren mit unterschiedlichen Schmelzpunkten zusammengesetzt sind, wenigstens als Schussfäden verwendet werden.
  7. Verstärkender Grundvliesstoff gemäß einem der Ansprüche 1 bis 6, wobei die flächige Form durch Schmelzverbindungen aufrechterhalten wird.
  8. Verstärkender Grundvliesstoff gemäß einem der Ansprüche 1 bis 7, wobei eine Vielzahl von verstärkenden Fasergarnen in derselben Richtung ausgerichtet sind.
  9. Verstärkender Grundvliesstoff gemäß einem der Ansprüche 1 bis 7, wobei die verstärkenden Fasern biaxiale Garnflächengebilde aus verstärkenden Fasern bilden, die aus einem Kettflächengebilde, bei dem die verstärkenden Fasergarne in Längsrichtung ausgerichtet sind, und einem Schussflächengebilde, bei dem die verstärkenden Fasergarne in Richtung der Breite ausgerichtet sind, bestehen.
  10. Verstärkender Grundvliesstoff gemäß einem der Ansprüche 1 bis 7, wobei die verstärkenden Fasern multiaxiale Garnflächengebilde aus verstärkenden Fasern bilden, die aus einem Garnflächengebilde aus verstärkenden Fasergarnen, die unter der Annahme, dass die Längsrichtung des Flächengebildes 0° entspricht, in 0°-Richtung ausgerichtet sind, einem Garnflächengebilde aus verstärkenden Fasergarnen, die in einer +α°-Richtung sowie in einer -α°-Richtung (0 < α < 90) ausgerichtet sind, und einem Garnflächengebilde aus verstärkenden Fasergarnen, die in einer 0°-Richtung und/oder in einer 90°-Richtung ausgerichtet sind, bestehen.
  11. Verstärkender Grundvliesstoff gemäß einem der Ansprüche 1 bis 10, wobei die flächige Form aus Multifilamenten gebildet wird, die einen Grad der Flachheit in einem Bereich von 20 bis 700 aufweisen.
EP20040723327 2003-10-01 2004-03-25 Vliesstoff als einlage Expired - Fee Related EP1669486B1 (de)

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CN100404744C (zh) 2008-07-23
KR20050114658A (ko) 2005-12-06
EP1669486A4 (de) 2008-11-05
US20060154020A1 (en) 2006-07-13
CN1761785A (zh) 2006-04-19
CA2533179A1 (en) 2005-04-14
CA2533179C (en) 2008-12-16
EP1669486A1 (de) 2006-06-14
WO2005033395A1 (ja) 2005-04-14
JP2005105492A (ja) 2005-04-21
KR100738754B1 (ko) 2007-07-12
JP3853774B2 (ja) 2006-12-06

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